1、Facilities Systems Completion Planning and ExecutionAPI RECOMMENDED PRACTICE 1FSC FIRST EDITION, JULY 2013Special NotesAPI publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.Neithe
2、r API nor any of APIs employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for an
3、y use, or the results of such use, of any information or process disclosed in this publication. Neither API nor any of APIs employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.API publications may be used by
4、 anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or resp
5、onsibility for loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publication may conflict.API publications are published to facilitate the broad availability of proven, sound engineering and operating practices. These publications are n
6、ot intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.Any manufacturer marking equipment o
7、r materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.Users of this Reco
8、mmended Practice should not rely exclusively on the information contained in this document. Sound business, scientific, engineering, and safety judgment should be used in employing the information contained herein.All rights reserved. No part of this work may be reproduced, translated, stored in a r
9、etrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, NW, Washington, DC 20005.Copyright 2013 American Petroleum InstituteForewor
10、dNothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone agai
11、nst liability for infringement of letters patent.Shall: As used in a standard, “shall” denotes a minimum requirement in order to conform to the specification.Should: As used in a standard, “should” denotes a recommendation or that which is advised but not required in order to conform to the specific
12、ation.May: As used in a standard, “may” is used to express permission or a provision that is optional.Can: As used in a standard, “can” is used to express possibility or capability.This document was produced under API standardization procedures that ensure appropriate notification and participation
13、in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which this publication was developed should be directed in writing to the Director of Standards, Ame
14、rican Petroleum Institute, 1220 L Street, NW, Washington, DC 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director.Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every f
15、ive years. A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is published annually by API, 1220 L Street, NW, Washington, DC
16、20005.Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17、 . . . . . . . . . . . . . . . . . . . . 12 Terms, Definitions, and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 Terms and Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18、. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Systems Completion Planning. . . . . . . . . . . . . . . . . . . . . .
19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.2 Planning and Organization. . . . . . . .
20、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Systems Completion Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.1 General . . . . . . . . . .
21、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.2 Factory Acceptance Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22、 54.3 Verification of Mechanical Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.4 Pre-commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23、 . . . . . . . . . 64.5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.6 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.7 Performance Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.8 Operations Assistance and Project Closeout . . . . . . . . . . . . .
25、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Annex A (informative) Turnover and Completions Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Figure1 Systems Completion Execution Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Table1 Systems Completion Planning and Organization Activit
27、ies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4vIntroductionThe systems completion process is the sequential activities within a project that verify and prove the construction, installation, integration, testing, and preparation of systems have been completed as desig
28、ned, and thus, the facility is ready for start-up and operations. The systems completion process is designed to help prepare and manage the transfer of care, custody, and control of facilities under construction through appropriate certification and documentation, such that the details of progress a
29、re evident. The systems completion process identifies two main phases in the project life cycle planning and execution. The planning phase begins in front-end engineering design (FEED) and comprises evaluation/planning through the beginning of fabrication/construction. The execution phase (field act
30、ivities) starts with factory acceptance tests (FATs) and ends with stable operations and acceptance of the facility by operations. Systems completion planning and execution activities overlap at detailed engineering and procurement and fabrication/construction.For many years the petrochemical indust
31、ry has prepared documents representing the combined knowledge and experience of the industry on various phases of petrochemical industry operations. In continuation of this effort, this recommended practice assembles in one document established processes, practices, and terminology to standardize sy
32、stems completion planning and execution within the petrochemical industry.vi1Facilities Systems Completion Planning and Execution1 ScopeThis document applies to a wide variety of projects within the oil and gas industry excluding subsurface. Although intended for oil and gas industry, the process de
33、scribed in this document can be applied to other industries as well. It is intended that the processes and practices established herein can be adapted and applied from a single piece of tagged equipment to a complex petrochemical facility. The process described within is intended to be applied at a
34、system level.2 Terms, Definitions, and Abbreviations2.1 Terms and DefinitionsFor the purposes of this document, the following terms and definitions apply.2.1.1 “A” check sheetA recorded verification that the equipment is mechanically complete.2.1.2 “B” check sheetA recorded verification that the equ
35、ipment has been energized and function tested per the engineering design specification.2.1.3 “C” check sheetA recorded verification that a system commissioning activity has been completed.2.1.4 commissioningGroup of energized and dynamic tests that constitute verification that each “system or subsys
36、tem” is fabricated, installed, cleaned, and tested in accordance with design and the systems are ready for start-up.2.1.5 certificateDocuments that the system is complete for each step of the process.2.1.6 mechanical completionMilestone point in time when tagged items and equipment within a system i
37、s installed in accordance with all drawings, specifications, and documented in accordance with the inspection test plan and is ready for pre-commissioning.2.1.7 handoverInternal transfer of assets based on either an area/module or systems determination between functional groups within the project or
38、ganization 2.1.8 inspection and test planDocument describing activities required to assure quality of manufacturing and installation. 2.1.9 inspection and test recordRecord documenting manufacturing and installation of equipment.2 API RECOMMENDED PRACTICE 1FSC2.1.10 function testingThe dynamic testi
39、ng of a tag or tags, components, or loops to confirm functionality.2.1.11 pre-commissioningGroup of energized and static tests that constitute verification that the “equipment or component” is fabricated, installed, cleaned, and tested in accordance with the design and ready for commissioning. NOTE
40、Also referred to as static commissioning.2.1.12 punch listA list of outstanding or unacceptable work associated with a component or system.2.1.13 “A” punch list itemOutstanding or non-conforming work associated with a component or system that is completed before pre-commissioning can begin.2.1.14 “B
41、” punch list itemOutstanding or non-conforming work associated with a component or system that is completed before commissioning can begin and prior to systems being put into operation.2.1.15 “C” punch list itemOutstanding or non-conforming work associated with a component or system that is complete
42、d prior to final facility acceptance.2.1.16 ready-for-commissioningMinor milestone in project when pre-commissioning activities for a discipline (electrical, instrumentation, mechanical, piping, etc.) are essentially complete and ready to commence commissioning.2.1.17 ready-for-start-upSignifies tha
43、t system construction, pre-commissioning, and commissioning work are complete and the required safety verification is ready to commence start-up. 2.1.18 subsystemPartial section of originally defined system that consists of interconnected items or group of equipment performing a specific utility or
44、operational service or function; will be able to be isolated and separated from the associated system for independent pre-commissioning.2.1.19 systemInterconnected items or group of equipment performing a specific utility or operational service or function; will be able to be isolated and separated
45、from the overall facility for independent pre-commissioning and commissioning.2.1.20 systems completionThe process through which the technical integrity and design of a newly built facility is verified and the new facility is turned over from the project to asset owner or from contractor to owner.FA
46、CILITIES SYSTEMS COMPLETION PLANNING AND EXECUTION 32.1.21 systems completion certification processThe process through which a system, subsystem, or piece of equipment has been installed, tested, and certified as ready to be put in service.2.1.22 systems completion databaseSoftware application that
47、provides the project management team and contractors with the means to organize and manage progress and certification of all systems completion activities.2.1.23 systems engineeringEngineering input to facility design from a systems completion perspective that encompasses functional systemization, c
48、ommissioning activities, start-up sequence, and the certification process ensuring the facility design can start-up as designed and planned.2.1.24 turnoverTransfer of care, custody, and control of a system from a contractor organization to a company organization.2.1.25 turnover and completion packag
49、eThe required documentation to define that a system has been built, installed, tested and is ready to be placed into operation.2.2 AbbreviationsFor the purposes of this document, the following abbreviations apply.FAT factory acceptance testFTP Functional Test ProcedureFEED front-end engineering designHAZID Hazard IdentificationIRN inspection release noticeLOTO lock out/tag outMC mechanical completionNDT nondestructive testingPFD process flow diagramPID piping and instrument diagramPSSR pre-start-up safety reviewPTW permit to workSAT site acceptance testSIT site integration testSC syste
